Hair removal device

ABSTRACT

A hair removal device includes a housing, an inner disc rotatably mounted to the housing and an outer disc rotatably mounted to the housing. The outer disc includes a body and a peripheral surface. The axial dimension of the peripheral surface is greater than an axial dimension of the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Nos. 61/449,570, filed Mar. 4, 2011, and 61/368,126, filedJul. 27, 2010, both of which are incorporated herein by reference intheir entireties.

BACKGROUND

The present invention relates generally to the field of hair removaldevices. The present invention relates specifically to hair removaldevices configured to remove hair by pulling and uprooting the hair fromthe skin.

Unwanted hair may be removed in a variety of ways. For example, hair maybe cut at or near the surface of the skin with a razor or other cuttingdevice. Typically, hair removed in this manner will re-grow quicklyrequiring frequent removal. In addition, hair may be removed via theapplication of a chemical, for example a depilatory cream, which acts todissolve the hair. Alternatively, various devices and techniques existto remove the entire hair including the root. Examples of such devicesand techniques include tweezers, epilators, waxing, etc. These devicesand techniques typically involve grasping the hair and the applicationof force to pull or pluck the hair and the root from the skin. Removalof hair by the root is usually longer-lasting than methods of hairremoval that only remove hair at the surface of the skin. However, theremay be discomfort associated with removal of hair by the root.

SUMMARY

One embodiment relates to a hair removal device including a housing, aninner disc rotatably mounted to the housing and an outer disc rotatablymounted to the housing. The outer disc includes a body and a peripheralsurface. The axial dimension of the peripheral surface is greater thanan axial dimension of the body.

In one embodiment, the body of the outer disc includes a central hub andat least one arm extending radially from the central hub, and theperipheral surface is the radially, outermost surface of the at leastone arm. In one embodiment, the at least one arm includes an innersection, and the axial dimension of the peripheral surface is greaterthan an axial dimension of the inner section of the at least one arm. Inone embodiment, the axial dimension of the peripheral surface is atleast two times greater than the axial dimension of the inner section ofat least one arm. In one embodiment, the material forming the peripheralsurface of the at least one arm is different than the material of theinner section of the at least one arm. In one embodiment, the materialforming the peripheral surface of at least one arm is a polymer materialand the material of the inner section of the at least one arm is ametal. In one embodiment, the axial dimension of the at least one armincreases as the radial distance from the center of the outer discincreases. In one embodiment, the axial dimension of the at least onearm reaches a maximum at the peripheral surface.

In one embodiment, the peripheral surface of the outer disc is a skincontacting surface and is configured to reduce discomfort associatedwith hair removal. In one embodiment, the inner disc and the outer dischave opposing surfaces configured to engage a hair. In one embodiment,the opposing surfaces of the inner disc and outer disc are substantiallyparallel to the radial axes of the discs, and the peripheral surface issubstantially perpendicular to the radial axes of the discs. In oneembodiment, the outer disc moves toward the inner disc to engage thehair.

In one embodiment, the hair removal device includes an insert coupled tothe outer disc and positioned between the inner disc and the outer disc.In this embodiment, the inner disc includes a first surface, and theinsert includes a second surface opposing the first surface, and theinsert and the inner disc are configured to engage a hair between thefirst and second surfaces. In one embodiment, the peripheral surface ofthe outer disc is made from a first material and the second surface ismade from a second material. In one embodiment, the first material is apolymer material and the second material is a metal. In one embodiment,the first surface is made from the second material. In one embodiment,the outer disc includes an inner axial surface and an outer axialsurface, and the insert is directly coupled to the inner axial surfaceof the outer disc.

Another embodiment relates to a hair removal device including a housing,an inner disc rotatably mounted to the housing and an outer discrotatably mounted to the housing adjacent to the inner disc. The innerdisc includes a first hair engagement surface. The outer disc includesan inner axial surface, a peripheral surface positioned to contact skinof a user and an outer axial surface. The hair removal device includesan insert coupled to the inner axial surface of the outer disc, and theinsert includes a second hair engagement surface facing the first hairengagement surface. The peripheral surface of the outer disc is madefrom a first material, and the second hair engagement surface is madefrom a second material. In one embodiment, the first material is apolymer material, and the second material is a metal. In one embodiment,the first hair engagement surface is made from the second material. Inone such embodiment, the second material is metal.

Another embodiment relates to a method of removing hair. The methodincludes rotating an inner disc and a pair of outer discs of a hairremoval device to cause the distance between opposing surfaces of theinner disc and outer discs to decrease and grasping a hair betweenopposing surfaces of an inner disc and outer discs. The method furtherincludes contacting the surface of the skin on either side of the hairwith peripheral surfaces of the outer discs, and resisting upwarddeformation of the skin during hair removal via the contact between theperipheral surfaces of the outer discs and the skin. In one embodiment,discomfort associated with hair removal is reduced by resisting upwarddeformation of the skin during hair removal.

Alternative exemplary embodiments relate to other features andcombinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements inwhich:

FIG. 1 is a top view of a hair removal device, according to an exemplaryembodiment;

FIG. 2 is an enlarged view of the head portion of the hair removaldevice of FIG. 1, according to an exemplary embodiment;

FIG. 3 is an exploded view of a disc assembly, according to an exemplaryembodiment;

FIG. 4 is a perspective view of the assembled disc assembly of FIG. 3,according to an exemplary embodiment;

FIG. 5 is a top view of the assembled disc assembly of FIG. 4, accordingto an exemplary embodiment;

FIG. 6 is a cross-sectional view of an outer disc of the disc assemblyof FIG. 4, according to an exemplary embodiment;

FIG. 7 is a sectional view showing a portion of the hair removal deviceof FIG. 1; and

FIG. 8 is a side sectional view of a portion of a disc assembly duringhair removal, according to an exemplary embodiment;

FIG. 9 is an exploded view of a disc assembly, according to anotherexemplary embodiment;

FIG. 10 is a perspective view showing an assembled outer disc andinsert, according to an exemplary embodiment;

FIG. 11 is a perspective view of the assembled disc assembly of FIG. 9,according to an exemplary embodiment;

FIG. 12 is a cross-sectional view of a portion of the disc assembly ofFIG. 9 in the closed position, according to an exemplary embodiment; and

FIG. 13 is an enlarged view of the head portion of the hair removaldevice, according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Referring to FIG. 1, a hair removal device, shown as epilator 10, isdepicted according to an exemplary embodiment. Epilator 10 includes ahousing 12. Housing 12 generally supports and provides mounting for thevarious components of epilator 10. In the embodiment shown, housing 12also defines a handle portion 14 and a head portion 16 of epilator 10.Handle portion 14 is shaped to provide a convenient and comfortablegripping surface to allow a user to hold and manipulate epilator 10during use. Epilator 10 includes an activation switch 18 located alonghandle portion 14. Activation switch 18 may be toggled between on andoff positions, allowing the user to activate and deactivate epilator 10.Epilator 10 also includes a hair plucking assembly 20 mounted to andsupported by housing 12. In the embodiment shown, hair plucking assembly20 is mounted to head portion 16 of housing 12.

Referring to FIG. 2, an enlarged view of head portion 16 of epilator 10is shown, according to an exemplary embodiment. As shown, hair pluckingassembly 20 includes a plurality of disc assemblies 22. Disc assemblies22 are rotatably mounted within head portion 16 of housing 12. In theembodiment shown, disc assemblies 22 are mounted to a curved shaft(shown in FIG. 7), resulting in the concave curvature of hair pluckingassembly 20 shown in FIG. 2. Further, each disc assembly 22 is identicalto the other disc assemblies 22 of epilator 10 except for the rotationalorientation of disc assembly 22 relative to the curved shaft.

As explained in more detail below, each disc assembly 22 is configuredto move between a “closed” configuration in which disc assembly 22 isconfigured to engage, grasp or trap a hair to be removed and an “opened”configuration in which any removed hair is released from the discassembly. As each disc assembly 22 rotates within head portion 16 aboutthe axis of the curved shaft, each disc assembly 22 alternates betweenthe “opened” and “closed” configurations. Further, if disc assembly 22has engaged a hair in the closed position, subsequent rotation of thedisc assembly 22 acts to pull the hair from the skin prior to the discassembly entering the “opened” configuration.

In the embodiment shown, each disc assembly 22 is rotationally offsetabout 60 degrees from the adjacent disc assemblies. This arrangementresults in a first set of alternating disc assemblies 22 assuming the“closed” configuration and a second set of alternating disc assemblies22 assuming the “opened” configuration. As shown in FIG. 2, the first,third, and fifth disc assemblies 22 are in the “closed” configuration,and the second and fourth disc assemblies 22 are in the “opened”configuration. In the embodiment shown in FIG. 2, if hair pluckingassembly were to rotate 60 degrees about the shaft axis, the first,third, and fifth disc assemblies 22 would assume the “opened”configuration, and the second and fourth disc assemblies 22 would assumethe “closed” configuration.

In one embodiment, hair plucking assembly 20 of epilator 10 may includea first row and a second row of substantially parallel disc assemblies22. In another embodiment, hair plucking assembly 20 of epilator 10 mayinclude a single row of disc assemblies 22. In other embodiments, hairplucking assembly 20 may include more than two rows of disc assemblies22 (e.g., three, four, five, six, etc.). Further, while FIG. 2 showshair plucking assembly 20 including five disc assemblies 22, in otherembodiments, each row may include more than five or less than five discassemblies. In one embodiment, each row of hair plucking assembly 20 mayinclude an odd number (e.g., one, three, seven, nine, etc.) of discassemblies 22, and, in another embodiment, each row of hair pluckingassembly 20 may include an even number (e.g., two, four, six, eight,etc.) of disc assemblies 22.

Referring to FIG. 3, an exploded view of disc assembly 22 is shownaccording to an exemplary embodiment. Each disc assembly 22 includes aninner disc, shown as internal disc assembly 24, and two outer discs 26.Each outer disc 26 includes a body 27 having a central hub 28 and threeradially extending arms 30. As shown, arms 30 are evenly spaced aroundcentral hub 28, such that the radial center axes of arms 30 are spacedabout 120 degrees from each other. As explained in more detail below,each arm 30 includes an inner section 32 and a wider outer section 34.Each outer section 34 of arms 30 includes an outer or peripheralsurface, shown as skin contacting surface 36, and a pair of lateralsurfaces, shown as hair engagement surfaces 37. Skin contacting surface36 is the radial, outermost surface of arms 30 that contacts the user'sskin during use of epilator 10 and is positioned substantiallyperpendicular to the radial center axis of each arm 30. The pair of hairengagement surfaces 37 are positioned on either side of skin contactingsurface 36 and are positioned substantially parallel to the radialcenter axis of each arm 30. Each outer disc 26 includes a centralaperture 38.

Internal disc assembly 24 includes an internal disc 40 and a disccarrier 42. Internal disc assembly 24 includes a mounting hub 44, acentral aperture 46 defined through mounting hub 44, and threeengagement protrusions 48 surrounding central aperture 46. Whenassembled to create hair plucking assembly 20, central aperture 46receives the curved shaft, and engagement protrusions 48 act to coupleinternal disc assembly 24 to the shaft such that rotation of the shaftis transferred to internal disc assembly 24. Further, engagementprotrusions 48 act to couple together adjacent disc assemblies 22 withinhair plucking assembly 20.

Internal disc 40 includes three radially extending arms 50 evenly spacedaround mounting hub 44 such that the radial center axes of arms 50 arespaced about 120 degrees from each other. Each arm 50 includes aradially outer or peripheral section 52. Each peripheral section 52includes a pair of lateral surfaces, shown as hair engagement surfaces54. Hair engagement surfaces 54 are positioned substantially parallel tothe radial center axis of each arm 50 and, in the orientation of FIG. 3,form the upper and lower surfaces of arms 50. As explained in moredetail below, during hair removal, when a disc assembly 22 is rotated tothe closed position, a hair may be grasped or engaged between hairengagement surface 37 of outer disc 26 and hair engagement surface 54 ofinternal disc 40 prior to removal.

Disc carrier 42 includes three U-shaped sections 56 spaced in betweenarms 50. Each U-shaped section 56 includes a pair of circumferentiallyfacing surfaces 58. As can be seen in FIG. 4, when assembled,circumferentially facing surfaces 58 of U-shaped section 56 engage outerdiscs 26, such that rotation of internal disc assembly 24 is imparted toouter discs 26 causing the components of disc assembly 22 to rotatetogether. Disc carrier 42 also includes protrusions 60 extending fromthe upper and lower surfaces of each of the U-shaped sections 56. Inoperation, protrusions 60 exert a force on the arms 30 of the outerdiscs of the adjacent disc assemblies 22. As can be best seen in FIG. 7,the interaction between protrusions 60 and arms 30 of adjacent discassemblies result in the movement of disc assemblies between the openedand closed configurations.

Referring to FIG. 4 and FIG. 5, disc assembly 22 is shown followingassembly. As shown, outer discs 26 are coupled to inner disc assembly 24by central aperture 38 of outer discs 26 receiving mounting hub 44.Further, each arm 50 of internal disc assembly 24 is positioned betweena pair of arms 30 of outer discs 26. Further, as shown best in FIG. 5,circumferential facing surfaces 58 of U-shaped section 56 engagecircumferential surfaces of arms 30 of outer discs 26 such that rotationof inner disc assembly 24 is imparted to outer discs 26.

In various embodiments, outer discs 26 are configured to reducediscomfort associated with the hair plucking process and are configuredsuch that the contact between the outer discs and the skin of the useris more comfortable. Referring to FIG. 6, a side sectional view of anouter disc 26 is shown according to an exemplary embodiment. As notedabove, in various embodiments, outer discs 26 include arms 30 having aninner section 32 and a wider outer section 34. Outer section 34 has askin contacting surface 36. As shown in FIG. 6, the axial dimension ofskin contacting surface 36, shown as W1, is greater than the axialdimension, shown as W2, of inner section 32. Thus, by providing a wideror thicker end section 34, skin contacting surface 36 of each arm 30 hasa greater surface area than if arms 30 had a constant narrower width ofW2 in the radial direction. Further, by providing only the end section34 of arm 30 with the increased width or thickness, the overall weightof outer disc 26 is less than if arms 30 had a constant greater width ofW1 along the radial length.

The contact between the user's skin and arms 30 may be made morecomfortable by increasing the contact surface area between the skin andouter discs 26. Further, the increased surface area of skin contactingsurface 36 may tend to compress and/or to increase the local skintension around the hair. This increase in skin tension around the hairtends to resist upward deformation of the skin during hair removal.Thus, by increasing the surface area of skin contacting surface 36, thetendency of the skin on either side of the hair to be pulled orstretched upward during hair removal is reduced resulting in increasedcomfort during hair plucking. Further, the efficiency of hair removalmay also be increased by the resistance of upward deformation of theskin provided by skin contacting surface 36. When the skin deformationis minimized, less force may be needed to be applied to the hair tocause removal.

As shown in FIG. 6, end section 34 has a substantially rectangularcross-section in the radial direction with an abrupt, stepped transition62 between inner section 32 and end section 34. In other embodiments,arms 30 of outer disc 26 may be of other shapes that provided for alarger skin contacting surface 36. For example, the radial cross-sectionof end section 34 may have a substantially triangular or trapezoidalshape such that the axial dimension W1 of the end section increasesgradually as the radial distance from the center of outer disc 26increases. In other embodiments, end section 34 may have a roundedradial cross-sectional shape. In various embodiments, the axialdimension of arm 30 reaches a maximum at skin contacting surface 36.

As shown in FIG. 6, W1 is greater than W2 such that the area of skincontacting surface 36 is larger than the circumferential cross-sectionalarea of inner section 32 of arm 30. In one embodiment, W1 is at leasttwo times greater than W2, and, in another embodiment, W1 is at leastthree times greater than W2. In one embodiment, W1 is between aboutthree and four times greater than W2, and specifically is about threeand a half times greater than W2. In various embodiments, W1 is betweenabout 0.5 mm and about 2.5 mm, specifically between about 1 mm and 2 mmand more specifically is between about 1.2 mm and 1.6 mm. In oneembodiment, W1 is about 1.4 mm. In various embodiments, W2 is betweenabout 0.1 mm and 1 mm, specifically between about 0.1 mm and 0.6 mm, andmore specifically between about 0.3 mm and 0.5 mm. In one embodiment, W2is about 0.4 mm. In another exemplary embodiment, W1 is about 1.4 mm andW2 is about 0.4 mm. In another embodiment, W1 is about 1.7 mm.

In one embodiment, end section 34 may be made from a material selectedto provide increased comfort associated with the contact between outerdisc 26 and the user's skin. In one embodiment, end section 34 may bemade from a polymer or plastic material. In one such embodiment, thematerial of end section 34 may be different from the material of innersection 32. For example, end section 34 may be made from a polymer orplastic material and other portions of outer disc 26, including innersection 32, may be made from metal (e.g., stainless steel). In otherembodiments, end section 34 and inner section 32 of arm 30 may be madefrom the same material. In one such embodiment, end section 34 mayinclude a layer or coating of material comprising skin contactingsurface 36. In one such embodiment, end section 34 and inner section 32may be made of metal (e.g., stainless steel) and the coating may be apolymer or plastic material. In another embodiment, outer disc 26 may bemade from a single material. In one such embodiment, outer disc 26 maybe made from a plastic material, and specifically may be integrallymolded from a polymer or plastic material.

As noted above, removal of hair by plucking may be uncomfortable orpainful. In the past, hair removal devices have addressed the discomfortassociated with hair removal in various ways. Some devices have utilizedadditional components or systems to decrease discomfort. For example,U.S. Pat. No. 6,436,106, which is incorporated herein by reference inits entirety, discloses a hair removal device with a vibration systemthat applies vibration to the skin to reduce discomfort associated withthe hair removal process. Other devices are designed such that hairs areremoved quickly from the skin thereby reducing discomfort. However,these devices do not provide for an increased skin contacting area toreduce discomfort. Further, these devices typically do not include anend section composed of a different material selected to increase thecomfort of skin contact. In one exemplary embodiment, epilator 10 doesnot include a vibration system or other separate system to decreasediscomfort. In another embodiment, epilator 10 may include both outerdiscs 26 with larger skin contacting surface 36 and a vibration systemor other system to reduce discomfort.

Referring back to FIG. 4, the relative size of skin contacting surface36 to components of inner disc assembly 24 can be seen. In theembodiment shown, the axial dimension, W1, of skin contacting surface 36is greater than the axial dimension of radial arm 50 of inner discassembly 24 (W3 shown in FIG. 8). In one embodiment, W1 is at least twotimes greater than the axial dimension of radial arm 50 of inner discassembly 24, and, in another embodiment, W1 is at least three timesgreater than the axial dimension of radial arm 50 of inner disc assembly24. In one embodiment, W1 is between about three and four times greaterthan the axial dimension of radial arm 50 of inner disc assembly 24, andspecifically is about three and a half times greater than the axialdimension of radial arm 50 of inner disc assembly 24. In anotherembodiment, W1 is between about four and five times greater than theaxial dimension of radial arm 50 of inner disc assembly 24, specificallybetween about 4 and 4.5 times greater than the axial dimension of radialarm 50 of inner disc assembly 24 and more specifically is about 4.25times greater than the axial dimension of radial arm 50 of inner discassembly 24. In various embodiments, the axial dimension of radial arm50 of inner disc assembly 24 is between about 0.1 mm and 1 mm,specifically between about 0.1 mm and 0.6 mm, and more specificallybetween about 0.3 mm and 0.5 mm. In one embodiment, the axial dimensionof radial arm 50 of inner disc assembly 24 is about 0.4 mm. In anotherexemplary embodiment, W1 is about 1.4 mm and the axial dimension ofradial arm 50 of inner disc assembly 24 is about 0.4 mm. In anotherexemplary embodiment, W1 is about 1.7 mm and the axial dimension ofradial arm 50 of inner disc assembly 24 is about 0.4 mm.

Referring to FIG. 7, a cross-sectional view of epilator 10 is shownaccording to an exemplary embodiment. Epilator 10 includes a motor 70configured to cause rotation of hair plucking assembly 20. In oneembodiment, motor 70 may be a D.C. motor. Epilator 10 may include abattery and/or other power source (e.g., photovoltaic cell). In otherembodiments, epilator 10 may include an AC power converter such thatepilator 10 may be plugged to a conventional wall outlet. Epilator 10includes a transmission system 72 configured to transmit energygenerated by motor 70 to hair plucking assembly 20. Transmission system72 includes a motor gear 74, a first step down gear 76, a second stepdown gear 78, a transmission gear 80 and an action gear 82. As shown inFIG. 7, hair plucking assembly 20 includes a bearing plate 84, a curvedshaft 86 and a bearing support 88. Rotation generated by motor 70 istransmitted via the gears of transmission system 72 to shaft 86, androtation of shaft 86 in turn causes rotation of disc assemblies 22 ofhair plucking assembly 20. The gears of transmission system 72 areconfigured such that the rotation generated by motor 70 is converted tothe proper rotational speed for hair plucking assembly 20. Bearing plate84 and bearing support 88 are configured to provide smooth rotation ofshaft 86.

The alternating operation of disc assemblies 22 of hair pluckingassembly 20 can be seen in FIG. 7. Disc assemblies 22 are coupled tocurved shaft 86 and to the adjacent disc assemblies 22 so that all discassemblies 22 rotate together at the same rate (i.e., in synch). Asshown, shaft 86 includes a concave curvature causing compression of theportions of disc assemblies 22 in front of shaft 86 (i.e., above shaft86 in the orientation of FIG. 7) and also causing separation of theportions of disc assemblies 22 behind shaft 86 (i.e., below shaft 86 inthe orientation of FIG. 7).

Operation of hair plucking assembly will be explained with reference tocentral disc assembly 90 shown in FIG. 7 with the understanding that theone or more disc assemblies of the hair plucking assembly operates in asimilar fashion. As noted above, during rotation of hair pluckingassembly 20, each disc assembly alternates between opened and closedconfigurations, and, as shown in FIG. 7, central disc assembly 90 isshown in the closed, hair grasping position. As disc assembly 90rotates, the compression caused by shaft 86 forces the protrusions 60 ofthe inner disc assemblies 24 on either side of disc assembly 90 toengage the lateral surfaces of inner sections 32 of arms 30 of outerdiscs 26. The engagement between protrusions 60 and outer discs 26causes hair engagement surfaces 37 to move toward and to engage thelateral surfaces of arm 50 of inner disc assembly 24. As shown in FIG.8, if a hair is present between arm 50 of inner disc assembly 24 and oneof the hair engagement surface 37 of outer discs 26 at this time, thehair 100 will be engaged or grasped between arm 50 and hair engagementsurface 37. As rotation of central disc assembly 90 continues, hair 100will be plucked from skin 102.

Each bearing support 88 includes an inwardly facing protrusion 104.Protrusion 104 operates in a manner similar to protrusions 60 of innerdisc assembly 24, in that protrusions 104 apply a force to the left mostand the right most outer discs 26 within hair plucking assembly 20. Thiscauses the hair engagement surfaces 37 of the left most and the rightmost outer discs 26 to move toward and to engage the outermost lateralsurfaces of the left most and right most arms 50.

FIG. 8 shows the operations of skin contacting surfaces 36 during hairremoval according to an exemplary embodiment. As shown in FIG. 8, skincontacting surfaces 36 contact the outer surface of skin 102 on eitherside of hair 100. Because of the increased surface area of the contact,particularly in relation to the diameter of hair 100, skin contactingsurfaces 36 resist the upward pull or deformation of a substantialsection of skin 102 surrounding hair 100 as hair 100 is plucked. Thisresistance of upward pull of the skin on either side of the hair isbelieved to decrease the discomfort associated with hair removal andincrease efficiency of hair removal as discussed above.

In various embodiments, such as the embodiment shown in FIGS. 9-12, theouter disc assembly may be constructed such that the hair engagementsurface provides for efficient or improved hair engagement properties.In some embodiments, the outer disc assembly may be constructed suchthat the hair engagement surface is made from a different material thanthe skin contacting surface. Further, in some embodiments, the outerdisc assembly may be configured to increase the radial dimension of thehair engagement surface to increase the surface area of the outer discassembly that participates in the grasping of the hair.

Referring to FIG. 9, an exploded view of an another exemplary discassembly is shown. Disc assembly 110 includes an internal disc assembly24, two outer discs 112, and two outer disc inserts 114. Outer discs 112are similar to outer discs 26 in most respects, except as discussedbelow. Like outer discs 26, outer discs 112 have a body 27, a centralhub 28, and three radially extending arms 30. Outer discs 112 have anexpanded or wider end section 116 at the end of each arm 30. Each endsection 116 has a peripheral surface, shown as skin contacting surface118, and a recess 120. Recess 120 is an axial depression formed on theside of end section 116 generally facing internal disc assembly 24.Recesses 120 receive inserts 114 and act to facilitate the attachmentinsert 114 to outer discs 112.

As shown in FIG. 9, disc assembly 110 includes two inserts 114, eachpositioned between one of the outer discs 112 and internal disc assembly24. Outer disc 112 includes an inner axial surface 122 generally facingthe outer axial surface 124 of insert 114. Insert 114 is a substantiallyplanar element and includes three arms 126 generally shaped to match theshape of the inner axial surface 122 of body 27 of outer disc 112. Asshown in FIG. 10, insert 114 is received within recess 120 of outer disc112 to couple insert 114 to outer disc 112. Insert 114 is coupled toouter disc 112 to form an outer disc assembly 130. With insert 114coupled to outer disc 112 as shown in FIG. 10, outer axial surface 124of insert 114 is in contact with and is substantially flush with theinner axial surface of outer disc 112 (both axial surfaces are shown inFIG. 9). Insert 114 is coupled to outer disc 112 such that insert 114rotates as outer disc 112 rotates within the housing of the epilator, asdiscussed above.

As noted above, end section 116 of outer disc 112 includes a peripheral,skin contacting surface 118. Insert 114 also includes a peripheralsurface, shown as skin contacting surface 128, located on the peripheralface of each arm 126. When insert 114 is coupled to outer disc 112, skincontacting surface 118 of outer disc 112 and skin contacting surface 128together define a peripheral surface, shown as skin contacting surface132, of the outer disc and insert assembly 130. Further, with insert 114coupled to outer disc 112, the inner axial facing surface 134 of insert114 faces inner disc assembly 24. As explained in more detail below, aportion of inner axial facing surface 134 defines the hair engagementsurface of outer disc assembly 130.

As shown in FIGS. 9 and 10, insert 114 and outer disc 112 are separatecomponents that are coupled or mounted together. In one embodiment,insert 114 may be directly coupled to outer disc 112 by mechanicalengagement or mechanical coupling between the components, such as bysnap-fit or press-fit arrangements. In other embodiments, insert 114 maybe coupled to outer disc 112 using other mechanisms. For example, in oneembodiment insert 114 is coupled to outer disc 112 using an adhesivematerial placed between insert 114 and outer disc 112. In anotherembodiment, insert 114 may be welded (e.g., via ultrasonic welding) toouter disc 112. In another embodiment, insert 114 may not beindependently coupled directly to outer disc 112 and may be held inplace between outer disc 112 and inner disc assembly 24 once assembledto the curved shaft (e.g., shaft 86). In one embodiment, outer disc 112may be made of plastic and may be molded on to insert 114.

Referring to FIG. 11, disc assembly 110 is shown following assembly. Asshown, outer discs 112 are coupled to inner disc assembly 24 asdiscussed above. As shown in FIG. 11, disc assembly 110 includes twoinserts 114, each positioned between inner disc assembly 24 and one ofthe outer discs 112. Further, each arm 50 of inner disc assembly 24 ispositioned between each of the inserts 114. When assembled, end sections116 of upper and lower outer discs 112, the upper and lower inserts 114and arm 50 of the inner disc assembly 24 form a tweezer assembly 136.

FIG. 12 shows a partial cross-sectional view of the assembled discassembly 110, showing tweezer assembly 136 in the closed position. Asshown in FIG. 12, the hair engagement surfaces 134 of inserts 114 facehair engagement surface 52 of arm 50. When disc assembly 110 assumes theclosed configuration shown in FIG. 12, at least a portion of hairengagement surface 134 comes into contact with hair engagement surface52 of arm 50, and if a hair is present between the two surfaces, thehair may be grasped between the surfaces. As discussed above, with ahair grasped or clasped between the two hair engagement surfaces, discassembly 110 rotates pulling the hair from the user's skin.

In one exemplary embodiment, outer disc 112 is made from one materialand insert 114 is made from a second, different material. The materialof outer disc 112 may be selected to provide good skin-contactingperformance (e.g., increased comfort, decreased irritation, etc.), andthe material of insert 114 may be selected to improve the ability ofinsert 114 to grasp the user's hair. In one specific embodiment, outerdisc 112 is made from a plastic or polymer material, and both insert 114and arm 50 of inner disc assembly 24 are made from metal (e.g.,stainless steel, aluminum, etc.). In this embodiment, the polymermaterial of skin contacting surface 118 of outer disc 112 may providefor a comfortable skin contacting surface. Further in this embodiment,the metal to metal contact of hair engagement surfaces 134 and 52provides for effective hair engagement. Thus, this embodiment providesfor the combination of the increased comfort associated with asubstantially plastic skin contacting surface and the efficient hairgrip provided by the metal to metal hair engagement surfaces. Inaddition, utilizing inserts 114 may decrease the noise generated duringoperation compared to a disc assembly including only plastic outer discs112. However, in other embodiments, outer disc 112 may be made from onetype of polymer material, and insert 114 may be made from another typeof material, such as a second type of polymer material, a ceramicmaterial, etc.

In various embodiments, the sizes or dimensions of the components ofdisc assembly 110 may be selected to provide improved comfort duringhair removal and for providing effective hair removal. As shown in FIG.12, W3 is the axial dimension of arm 50 of inner disc assembly 24, W4 isthe axial dimension of insert 114, W5 is the axial dimension of skincontacting surface 118 of outer disc 112, and W6 is the axial dimensionof the entire skin contacting surface of tweezer assembly 136. In oneembodiment, W3 and W4 are substantially the same. In another embodiment,W5 is at least two times greater than W3 and/or W4, and, in anotherembodiment, W5 is between two and five times greater than W3 and/or W4.In one embodiment, W5 is between about three and four times greater thanW3 and/or W4. In various embodiments, W3 and/or W4 is between about 0.1mm and 1 mm, specifically between about 0.1 mm and 0.6 mm, and morespecifically between about 0.3 mm and 0.5 mm. In one embodiment, W3and/or W4 is about 0.4 mm. In various embodiments, W5 is between about0.5 mm and about 3 mm, specifically between about 1 mm and 2 mm, andmore specifically between about 1.4 mm and 2 mm. In one embodiment, W5is about 1.7 mm. In one embodiment, W3 and W4 are about 0.4 mm and W5 isabout 1.7 mm, and W6 is about 3.8 mm.

The circumferential length of tweezer assembly 136 may also be selectedto provide for efficient and comfortable hair removal. Referring back toFIG. 10, L1 represents the circumferential length of the skin contactingportion of insert 114 which is also the same as the circumferentiallength of tweezer assembly 136. In various embodiments, L1 is betweenabout one time and three times greater than W6, specifically is betweenabout 1.3 and 2 times greater than W6, and more specifically betweenabout 1.5 and 1.6 times greater than W6. In various embodiments, L1 isbetween about 3 mm and 9 mm, specifically between about 5 mm and 7 mm,and more specifically, between about 5.5 mm and 6.5 mm. In oneembodiment, L1 is about 6 mm.

FIG. 13 shows an enlarged view of the head portion of an epilator 10including disc assemblies 110. Similar to hair plucking assembly 20shown in FIG. 2, in the embodiment shown in FIG. 13, epilator 10includes a hair plucking assembly 138 including a plurality of discassemblies 110. Hair plucking assembly 138 operates in the same manneras hair plucking assembly 20 discussed above, except that inserts 114contact arms 50 of inner discs 24 during hair removal.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. While the currentapplication recites particular combinations of features in the claimsappended hereto, various embodiments of the invention relate to anycombination of any of the features described herein whether or not suchcombination is currently claimed, and any such combination of featuresmay be claimed in this or future applications. Any of the features,elements, steps or components of any of the exemplary embodimentsdiscussed above may be used alone or in combination with any of thefeatures, elements, or components of any of the other embodimentsdiscussed above. Although only a few embodiments have been described indetail in this disclosure, many modifications are possible (e.g.,variations in sizes, dimensions, structures, shapes and proportions ofthe various elements, values of parameters, mounting arrangements, useof materials, colors, orientations, etc.) without materially departingfrom the novel teachings and advantages of the subject matter describedherein. Some elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of anyprocess, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

1. A hair removal device comprising: a housing; an inner disc rotatablymounted to the housing; and an outer disc rotatably mounted to thehousing, the outer disc comprising: a body; and a peripheral surface;wherein the axial dimension of the peripheral surface is greater than anaxial dimension of the body.
 2. The hair removal device of claim 1,wherein the body of the outer disc comprises a central hub and at leastone arm extending radially from the central hub, wherein the peripheralsurface is the radially, outermost surface of the at least one arm. 3.The hair removal device of claim 2, wherein the at least one armcomprises an inner section, wherein the axial dimension of theperipheral surface is greater than an axial dimension of the innersection of the at least one arm.
 4. The hair removal device of claim 3,wherein the axial dimension of the peripheral surface is at least twotimes greater than the axial dimension of the inner section of the atleast one arm.
 5. The hair removal device of claim 3, wherein thematerial forming the peripheral surface of the at least one arm is apolymer material.
 6. The hair removal device of claim 5, wherein thematerial of the inner section of the at least one arm is a metal.
 7. Thehair removal device of claim 2, wherein the axial dimension of the atleast one arm increases as the radial distance from the center of theouter disc increases.
 8. The hair removal device of claim 7, wherein theaxial dimension of the at least one arm reaches a maximum at theperipheral surface.
 9. The hair removal device of claim 1, wherein theperipheral surface is a skin contacting surface and is configured toreduce discomfort associated with hair removal.
 10. The hair removaldevice of claim 1, wherein the inner disc and the outer disc includeopposing surfaces configured to engage a hair.
 11. The hair removaldevice of claim 10, wherein the opposing surfaces of the inner disc andouter disc are substantially parallel to the radial axes of the discs,and the peripheral surface is substantial perpendicular to the radialaxes of the discs.
 12. The hair removal device of claim 10, wherein theouter disc moves toward the inner disc to engage the hair.
 13. The hairremoval device of claim 1, further comprising an insert coupled to theouter disc and positioned between the inner disc and the outer disc,wherein the inner disc includes a first surface and the insert includesa second surface opposing the first surface, wherein the insert and theinner disc are configured to engage a hair between the first and secondsurfaces.
 14. The hair removal device of claim 13, wherein theperipheral surface of the outer disc is made from a first material andthe second surface is made from a second material.
 15. The hair removaldevice of claim 14, wherein the first material is a polymer material andthe second material is a metal.
 16. The hair removal device of claim 14,wherein the first surface is made from the second material.
 17. The hairremoval device of claim 13, wherein the outer disc includes an inneraxial surface and an outer axial surface, wherein the insert is directlycoupled to the inner axial surface of the outer disc.
 18. A hair removaldevice comprising: a housing; an inner disc rotatably mounted to thehousing, the inner disc including a first hair engagement surface; andan outer disc rotatably mounted to the housing adjacent the inner disc,the outer disc comprising: an inner axial surface; a peripheral surfacepositioned to contact skin of a user; and an outer axial surface; and aninsert coupled to the inner axial surface of the outer disc, the insertincluding a second hair engagement surface facing the first hairengagement surface; wherein the peripheral surface of the outer disc ismade from a first material and the second hair engagement surface ismade from a second material
 19. The hair removal device of claim 18,wherein the first material is a polymer material and the second materialis a metal.
 20. The hair removal device of claim 18, wherein the firsthair engagement surface is made from the second material.
 21. The hairremoval device of claim 20, wherein the second material is metal.
 22. Amethod of removing hair comprising: rotating an inner disc and a pairouter discs of a hair removal device to cause the distance betweenopposing surfaces of the inner disc and outer discs to decrease;grasping a hair between opposing surfaces of an inner disc and outerdiscs; contacting the surface of the skin on either side of the hairwith peripheral surfaces of the outer discs; and resisting upwarddeformation of the skin during hair removal via the contact between theperipheral surfaces of the outer discs and the skin.
 23. The method ofclaim 22 wherein discomfort is reduced by resisting upward deformationof the skin during hair removal.